Stations for treating motor-vehicle bodies and/or motor-vehicle components

ABSTRACT

A station for treating motor-vehicle bodies and/or components may include: a booth including at least one entrance for a motor-vehicle body and/or component and at least one exit for the motor-vehicle body and/or component; a system configured to move the motor-vehicle body and/or component between the at least one entrance and the at least one exit; at least one robot configured to treat the motor-vehicle body and/or component in the booth by spraying fluid toward the motor-vehicle body and/or component; and a platform inside the booth configured to support the motor-vehicle body and/or component. The system may be configured to rotate with the platform so as to align with the at least one entrance in order to receive the motor-vehicle body and/or component, and so as to align with the at least one exit in order to release the motor-vehicle body and/or component. The booth may have an octagonal shape.

The present invention relates to stations and plants for treating thesurfaces of objects, for example in particular in paint shops in theautomotive sector and, in particular, for treating the surfaces ofmotor-vehicle bodies and/or components, passing through the booth forthe application of different types of materials depending on thedifferent application cycles for painting, sealing, cleaning, preparingthe surfaces or quality control and more generally all thoseapplications where this invention may be adapted inside what isinternationally referred to as the “paint shop”.

In the prior art automatic stations comprising a booth equipped withrobots which carry out a processing cycle are known.

Usually, these stations, which are arranged in sequence longitudinally,form a surface-treatment plant passed through by a conveyor line.

In the known plants, an object, such as a vehicle body/part, enters intothe booth and remains inside it for the entire treatment time, while thearticulated robots are moved and displaced so as to cover the entirearea of the part to be treated, it therefore being possible to carry outthe required process which is performed with a suitable applicator orwith a specific apparatus designed to allow the planned processingoperation. Normally at least two robots are used for each booth, beingarranged on the two sides of the part to be treated, so that each ofthem can operate on the side assigned to it. The robots generally have arelatively high reach so as to be able to access, on the assigned side,all the points of the object (including objects with relatively largedimensions such as a vehicle body), and are somewhat costly.

Booths have been proposed where there is a single robot arranged abovethe object so as to be able to reach independently all the points of theobject, but this gives rise to various problems including the fact that,owing to the arrangement of the robot above the vertical axis of theobject, dripping or deposition of dust or the like onto the objectitself may occur, ruining the final appearance of the treatment (inparticular the paintwork).

Another very pressing problem affecting spray-painting booths is theneed to recover and treat the so-called over-spray, namely the quantityof paint which is atomized inside the booth and which does not reach thesurface. This over-spray in fact remains suspended in the air of thebooth and must therefore be propelled into the area underneath the boothfor treatment. The quantity of air necessary for elimination of thepaint fumes is therefore a significant parameter for the purposes ofenergy consumption.

A further problem of the known plants is that the sequential arrangementof the booths must be in a straight line, with the entrance and exit ofeach booth located on opposite sides of the booth. This preventsoptimized and efficient use of the space available in the plant.

The general object of the present invention is to provide innovativebooth stations for the treatment of surfaces of objects, which are ableto operate easily also with a single robot over the entire surfaces ofthe object to be treated.

Moreover, a further object of the present invention is to providepainting stations with a reduced over-spray zone. This is made possibleby moving the parts to be treated in various zones, instead of therobot.

Yet another object of the present invention is to provide plants whichallow better optimization of the spaces occupied and greaterflexibility.

In view of these objects the idea which has occurred is to provide,according to the invention, a station for treating objects according toclaim 1.

According to an embodiment of the invention the idea which has occurredis also to provide a station for treating objects, comprising a boothwith at least one entrance and at least one exit for an object, a systemfor moving the object between entrance and exit and at least onetreatment robot in the booth, characterized in that it comprises insidethe booth a support for supporting an object which enters the booth,which support is motor-driven to rotate about a vertical axis so as todirect sequentially towards the treatment robot different sides of theobject present on the support.

Still according to the invention, the idea which has occurred is toprovide plants formed by a plurality of these booths.

In order to illustrate more clearly the innovative principles of thepresent invention and its advantages compared to the prior art, anexample of embodiment applying these principles will be described belowwith the aid of the accompanying drawings. In the drawings:

FIG. 1 shows a schematic plan view of an embodiment of a stationaccording to the invention;

FIG. 2 shows a schematic side elevation view of a station according tothe invention;

FIG. 3 shows a schematic plan view of a plant according to theinvention;

FIG. 4 shows a schematic plan view of an alternative embodiment of astation according to the invention and a plant provided with a pluralityof these stations.

With reference to the Figures, FIG. 1 shows in schematic form atreatment station designed in accordance with the invention andindicated overall by 10.

The station 10 comprises a booth 10 provided with at least one entrance12 and at least one exit 13 for an object 14 to be treated. The objectmay be advantageously a motor-vehicle body or part. Advantageously, theobjects arrive at the entrance 12 by means of an entry conveyor system15 and leave the exit 13 by means of an exit conveyor system 16. Theseconveyor systems 15 and 16 are of the type known per se (for examplecomprising motor-driven rollers, a rack, a chain, etc.). and thereforemay be easily imagined by the person skilled in the art. They willtherefore not be further described or shown.

The booths may also comprise systems for suction and treatment of theover-spray, of the type known per se and therefore not shown in detail.

The booth has internally at least one process or treatment robot 17 (ofthe type known per se) and a handling system 18 designed to receive theobject from the entry conveyor system and, after treatment, to releasethe object to the exit conveyor system. The treatment may advantageouslyconsist of spray-painting and in this case the robot is a paintingrobot.

The booth also has a platform or support 23 which is motor-driven so asto rotate the object about a vertical axis 19, advantageously in acentral position of the object to be treated. Preferably, the rotationabout the axis 19 allows the various sides of the object to be processedto be arranged opposite the robot 17. The platform 23 may form part ofthe handling system 18 such that the latter also rotates about the axis19 so that it can be used in various angular positions, as will becomeclear below.

The entrances and exits of the booths may be aligned and face each otheron opposite sides of the booth (as shown for example in continuous linesin FIG. 1) or may be arranged unaligned (in particular on the sides ofthe booth not facing each other, as shown for example in broken lines inFIG. 1 for the exits).

In the first case the handling system 18, when rotated into a positionfor alignment of the entrance and exit, may form a direct connectionbetween the entry conveyor system 15 and the exit conveyor system 16,while in the second case the handling system 18 may be rotatedalternately into alignment with the entry conveyor system 15 and intoalignment with the exit conveyor system 16, in order to receive ordischarge, respectively, an object passing through or to be treated.

Advantageously, the platform 23 also comprises means 24 which form asystem for the alternate displacement, inside the booth, of the object14 along its longitudinal path (or main axis, namely the axis ofgreatest extension of the object, which is usually also the axis ofadvancing movement of the object along the treatment plant). In thiscase, the system 20 for controlling the station advantageously controlsin synchronism the movement of the robot and the displacement of theobject such as to displace alternately the object along the longitudinalaxis depending on the painting movement of the robot. The synchronousmovement allows the surface area of the object which is facing the robotfor painting to be increased. This for example allows a robot with asmaller lateral reach to be provided, the displacement movement of theobject defining in fact an axis of horizontal relative movement betweenthe surface to be treated and the robot applicator. Advantageously,during painting/treatment, the displacement movement may be performedtransversely opposite the robot. With this function the over-spray willbe concentrated in a small well-defined zone.

The system 20 may be a computerized electronic control system, which issuitably programmed, of the type known per se.

Advantageously the displacement means are formed by the same system 18which performs the entry and exit movement.

The control system 20 may also cause rotation of the object about thevertical axis 19 in synchronism with the robot and/or the displacementmovement.

The movements of the object inside the booth will also depend on themethods chosen for the application operations and/or the shape and sizeof the object.

For example, the rotation may be simply a complete rotation through 180°in order to position opposite the robot firstly one flank or side of theobject and then the opposite flank or side. In this way, the object maybe processed on one side in the first position, rotated through 180° andprocessed on the opposite side. The treatment is thus performed on bothsides without further rotational movements, but, at the most, with onlydisplacement movements of the object along the longitudinal axis.

Alternatively, the rotation may also be performed in steps smaller than180° so as to arrange facing the robot various successive lateralportions of the object, with the robot which gradually treats theseportions until completion of the surface to be treated.

The handling system 18 and the displacement system may have variousforms depending on the movement adopted and the type of object, forexample in the case of vehicle bodies/articles moved along the conveyorline.

In particular, in the case of vehicle bodies/articles positioned onconveyor skids 21, usually provided with two parallel sliding runners,two rows of motor-driven rollers 22, on which the runners of the skidentering the booth may rest, can be used. Suitable guide rails may alsobe provided. The same rollers may form both the handling system and themeans for alternating displacement of the article inside the booth.

The entry conveyor system 15 will insert the skid with the vehiclebody/article on the handling system 18 (aligned with the entrance 15)which will assume control of it until it is centred in the rotatingplatform. Thereafter the rotational and/or displacement movement willbring the various parts of the vehicle body/article into the operatingradius of the robot until the surface treatment operations have beencompleted. At the end, the platform will be rotated so as to align thehandling system with the exit 13 and the vehicle body/article will beunloaded by the handling system 18 onto the exit conveyor system 16 andevacuated from the station so as to continue towards successiveprocessing stations.

As can be clearly seen in the figures, although the booth may havevarious shapes (including a rectangular shape or also a circular shapein plan view, which may optimize its internal volume) in order tooptimize the internal space of the booth and its functionality it hasbeen found to be advantageous to design the booth with a polygonal,preferably rectangular shape, having more than four sides.

In particular, an octagonal shape (as shown in FIGS. 1 and 3) orhexagonal shape (as shown in FIG. 4) has been found to be especiallyadvantageous.

The booth may advantageously have at least one entrance and one exit onrespective sides of the polygon and a robot arm on the other side of thepolygon. Alternatively, as for example shown in FIG. 4, the robot may bearranged in a corner (or the booth may have another transverse sideinstead of the corresponding corner of the regular form).

The hexagonal or octagonal plan-view shape is preferable mainly becauseit allows the size thereof to be suitably chosen (for example so as toinscribe the circumference defined by rotation of the object by means ofthe internal handling system) and at the same time allows optimizationof the station volume, with the possibility of obtaining substantiallyflat internal walls which can be more easily manufactured and used.

The reduction in the internal volume compared, for example, to arectangular shape results in smaller amounts of air needed forelimination of the overspray.

As schematically shown in FIG. 2, the robot arm may be advantageouslyarranged so that at least in a rest position it is situated at a greaterheight than the object on the handling system, such as to allow rotationof the object with minimum play relative to the side walls of the booth,avoiding at the same time interference with the robot. This isparticularly useful in the case of long objects, such as motor-vehiclebodies.

Moreover, as can be clearly seen from the figures, as a result of thepolygonal shape with more than four sides, it is possible to obtain, asrequired, flat entrance and exit walls in the booth which are arrangedfacing each other on opposite sides, at right angles or at an angle inbetween the two.

FIGS. 3 and 4 show examples of treatment plants provided with aplurality of stations according to the invention.

As can be seen from the figures, the space occupied by the plant may bebetter used owing to the presence of the platform for rotating thebodies/articles and the possibility of having entrances and exits atvarious angles around the booth. It is in fact possible to provide aplant in which at least some of the stations of the plurality arearranged alongside each other in the two directions so as to obtain aplant where the occupied space is made better use of. Advantageously, atleast some of the stations of the plurality may have at least oneentrance and at least one exit arranged at angles with respect to eachother.

In this way it is possible to define more easily within the plant a pathwhich passes through the stations and which is not straight.

In particular, by using an octagonal or hexagonal shape it is possibleto obtain easier arrangement, next to each other or facing each other,of the exit of one booth with the entrance of the next booth dependingon the choice of various useful configurations. As can be seen in FIGS.3 and 4, the configurations may for example be advantageously describedas being of the “checkerboard” or “honeycomb” type.

Moreover, it is also possible to provide multiple entrances and/or exitsin a same booth so as to obtain several alternative paths along theplant, for example so as to differentiate between the treatments,depending on the incoming part to be treated. It is also possible toprovide multiple entrances into and/or exits from the plant, for exampleagain with conveyor systems 15 and 16.

The entry conveyor system 15 and the exit conveyor system 16 between twobooths may be easily the two ends of a same, albeit very short, conveyorsystem or may also be formed by the handling system of the preceding orfollowing booth arranged alongside or at a short distance, as may beeasily imagined with the reference to the same FIGS. 3 and 4.

With the hexagonal booths it is possible in various cases to obtain abetter use of the space in the plant (for example with the “honeycomb”arrangement which can be seen in FIG. 4), albeit with a slight increasein the internal volume, than with the octagonal booths (more easilyarranged in “checkerboard” fashion). The connection between one boothand another may also be performed by means of a connection tunnel whichmay also have the function of providing a further manoeuvring space foroptimum positioning of the article to be treated.

As can be seen for example in FIG. 4, the robot may be arranged on awall of the booth or in a corner between two walls, or in bothlocations.

Advantageously, the platform will rotate the object so as to position itpreferably with its main axis arranged transversely facing the robot, asfor example shown in FIG. 4 for the booth situated at the bottom on theleft, such that the entire side of the object faces the robot. Once thefirst side has been processed, the object may be rotated through 180° sothat its opposite side is arranged facing the robot.

Obviously, the arrangement shown in FIG. 3 is provided merely by way ofexample and a plant according to the invention may have differentarrangements depending on the specific needs.

Moreover, the painting stations may have, arranged between them atintervals, stations for performing other known treatments such as:cleaning, sanding, sealing, soundproofing, quality control, etc., inaddition to the known ones, such as drying ovens or the like. Within theplant, the stations according to the invention may also be easilyarranged at intervals with painting stations, or the like, which mayalso have a different shape, for example a rectangular or square shape,and the octagonal stations may be combined with hexagonal stations,depending on the requirements.

As is now obvious to the person skilled in the art, the stations mayalso be arranged at a distance from each other, while also maintainingthe more or less regular “checkerboard” or “honeycomb” arrangementsshown in FIGS. 3 and 4, for example so as to define walkways betweenthem useful for the transit of maintenance personnel or as a passagewayfor other service systems.

At this point it is clear how the predefined objects have been achieved.

Obviously the description above of an embodiment applying the innovativeprinciples of the present invention is provided by way of example ofthese innovative principles and must therefore not be regarded aslimiting the scope of the rights claimed herein. For example, forspecific needs, it is nevertheless possible to envisage providingseveral robot arms in a same booth according to the invention. Moreover,the term “painting” must be understood in the broad sense, namely thatthe fluid sprayed by the robot arm must not be necessarily a paint, butmay also be another surface treatment fluid or a fluid for performingoperations envisaged in application processes carried out on articleswhich are produced and treated in particular in the automotive sector.As mentioned, the system for moving the object, and in particular thevehicle body, between entrance and exit of the booth may also beseparate from the alternate handling means inside the booth, although asingle construction on the rotating support platform is preferable. Thenumber of stations in a plant may obviously vary and may also compriseonly two stations arranged for example so as to have an entry directioninto the plant and an exit direction from the plant, arranged at anangle with respect to each other.

1-10. (canceled)
 11. A station for treating motor-vehicle bodies and/ormotor-vehicle components, the station comprising: a booth comprising atleast one entrance for a motor-vehicle body and/or motor-vehiclecomponent and at least one exit for the motor-vehicle body and/ormotor-vehicle component; a system configured to move the motor-vehiclebody and/or motor-vehicle component between the at least one entranceand the at least one exit; at least one robot configured to treat themotor-vehicle body and/or motor-vehicle component in the booth byspraying fluid toward the motor-vehicle body and/or motor-vehiclecomponent; and a platform inside the booth configured to support themotor-vehicle body and/or motor-vehicle component; wherein the platformis configured to rotate about a vertical axis so as to rotate themotor-vehicle body and/or motor-vehicle component inside the boothrelative to the at least one robot, wherein the system configured tomove the motor-vehicle body and/or motor-vehicle component is configuredto rotate with the platform so as to align with the at least oneentrance in order to receive the motor-vehicle body and/or motor-vehiclecomponent, and so as to align with the at least one exit in order torelease the motor-vehicle body and/or motor-vehicle component, whereinthe booth has in plan view an octagonal shape, and wherein the least oneentrance and the at least one exit are arranged on sides of the boothnot facing each other so that the at least one entrance is not alignedwith the at least one exit.
 12. The station of claim 11, wherein the atleast one robot is arranged on a side of the booth which is differentfrom the sides of the least one entrance and the at least one exit. 13.The station of claim 11, wherein the at least one robot is arranged in acorner of the octagonal shape.
 14. The station of claim 11, wherein thebooth comprises more than one entrance and/or more than one exit, eachon different sides of the octagonal shape.
 15. The station of claim 11,wherein the least one entrance and the at least one exit are arranged onsides of the octagonal shape which are angulated by 45° or 90° or 135°with respect to each other.
 16. The station of claim 11, wherein thesystem configured to move the motor-vehicle body and/or motor-vehiclecomponent comprises motor-driven rollers suitable for a controlledtravel movement of a skid for conveying the motor-vehicle body and/ormotor-vehicle component.
 17. The station of claim 16, wherein themotor-driven rollers are placed in two parallel rows of motor-drivenrollers suitable to slide two parallel sliding runners of the skid forconveying the motor-vehicle body and/or motor-vehicle component.
 18. Thestation of claim 11, wherein the system configured to move themotor-vehicle body and/or motor-vehicle component is at least partiallymounted onto the platform.
 19. The station of claim 11, wherein theoctagonal shape is a regular octagon.
 20. The station of claim 11,wherein the fluid comprises paint.
 21. The station of claim 11, whereinthe at least one robot is arranged on a side of the booth which isdifferent from the side of the least one entrance.
 22. The station ofclaim 11, wherein the at least one robot is arranged on a side of thebooth which is different from the side of the least one exit.
 23. Thestation of claim 11, wherein the booth comprises more than one entrance,each on different sides of the octagonal shape.
 24. The station of claim11, wherein the booth comprises more than one exit, each on differentsides of the octagonal shape.
 25. The station of claim 11, wherein theleast one entrance and the at least one exit are arranged on sides ofthe octagonal shape which are angulated by 45° with respect to eachother.
 26. The station of claim 11, wherein the least one entrance andthe at least one exit are arranged on sides of the octagonal shape whichare angulated by 90° with respect to each other.
 27. The station ofclaim 11, wherein the least one entrance and the at least one exit arearranged on sides of the octagonal shape which are angulated by 135°with respect to each other.
 28. The station of claim 11, wherein thesystem configured to move the motor-vehicle body and/or motor-vehiclecomponent is mounted onto the platform.
 29. The station of claim 11,wherein the fluid is paint.
 30. The station of claim 11, wherein thefluid comprises fluid other than paint.